Ophthalmic lens manufacturing method, system, and apparatus that include flash removal from lens mold members
AssigneeCooperVision International Holding Company, LP
InventorsAlvin N. Irizarry Martell, Mark Reynolds, John Leone, James Cook
Life of this patent
Estimating the term…
Abstract
Methods, systems, and apparatus for removing flash from contact lens mold members are described. Flash is removed from contact lens mold members by cutting the flash from the mold member. The flash is removed by rotating a deflashing element or rotating a mold member, or both. After the flash is removed, the unfinished contact lens attached to the mold member can be further processed, which may include cutting an optical surface onto the contact lens.
Claims28
Apparatus for removal of flash from a contact lens mold member following manufacture of an unfinished polymerized contact lens body in a mold assembly, the contact lens mold member comprising a mold surface for carrying an unfinished polymerized contact lens body and a peripheral surface, the apparatus comprising:
- a support for supporting the mold member during de-flashing;
- a de-flashing element for separating flash from the peripheral surface of the mold member, the de-flashing element comprising a cutting edge;
- an axial driver arranged to bring together the de-flashing element and the mold member supported on the support such that at least a portion of the cutting edge is in a position proximal to the peripheral surface of the mold member;
- and
- a rotary driver arranged to rotate the de-flashing element and/or the mold member supported on the support relative to each other when at least a portion of the cutting edge is proximal to the peripheral surface of the mold member, thereby separating flash from the peripheral surface of the mold member.
A method of manufacturing a contact lens comprising:
- receiving at least one unfinished polymerised contact lens body in at least one contact lens mold assembly, wherein each contact lens mold assembly comprises a first mold member and a second mold member assembled together, and the first mold member comprises a mold surface and a peripheral surface;
- demolding the mold assembly so that the first mold member is separated from the second mold member and the unfinished polymerized contact lens body remains on the first mold member;
- bringing together a de-flashing element, comprising a cutting edge, and the first mold member such that at least a portion of the cutting edge is in a position proximal to the peripheral surface of the first mold member;
- and
- rotating the de-flashing element and/or the first mold member relative to each other thereby separating flash from the peripheral surface of the first mold member.
A system for manufacturing contact lenses, comprising:
- a contact lens mold assembly receiver configured to receive contact lens mold assemblies containing polymerized unfinished contact lens products disposed between first and second contact lens mold members;
- a contact lens assembly demolder configured to receive at least one contact lens mold assembly from the contact lens mold assembly receiver and to separate the first and second contact lens mold members;
- and
- a de-flashing apparatus configured to remove flash from the demolded contact lens mold member to which the polymerized unfinished contact lens product is attached, wherein the de-flashing apparatus comprises
- a support for supporting the mold member during de-flashing;
- a de-flashing element for separating flash from the peripheral surface of the mold member, the de-flashing element comprising a cutting edge;
- an axial driver arranged to bring together the de-flashing element and the mold member supported on the support such that at least a portion of the cutting edge is in a position proximal to the peripheral surface of the mold member;
- and
- a rotary driver arranged to rotate the de-flashing element and/or the mold member supported on the support relative to each other when at least a portion of the cutting edge is proximal to the peripheral surface of the mold member, thereby separating flash from the peripheral surface of the mold member.
Dependencies are inferred from the claim text.